Suzuki SV650A Supplementary Service Manual

SV650/S/A/SA

USE THIS MANUAL WITH:

SV650 SERVICE MANUAL (99500-36123-01E)

99501-36140-01E

SV650K7/SK7/AK7/SAK7 (’07-MODEL) 1

CONTENTS

SV650K7/SK7/AK7/SAK7 (’07-MODEL)

This manual describes service data, service specifications, servicing procedures ABS and ser-

vicing procedures which differ from those of the SV650K6/SV650SK6 (’06-model).

NOTE:

• Any differences between the SV650K6/SV650SK6 (’06-model) and SV650K7/

SV650SK7 (’07-model) in specifications and service data are indicated with an asterisk

mark (*).

• Any differences between the SV650K7/SV650SK7 (’07-model) and SV650AK7/

SV650SAK7 (’07-model) in specifications and service data are indicated with an aster-

isk mark (**).

• Please refer to the SV650SK6 (’06-model) service manual for details which are not

given in this manual.

COUNTRY AND AREA CODES....................................................................... 3

ABBREVIATIONS USED IN THIS MANUAL ................................................... 4

SAE-TO-FORMER SUZUKI TERM .................................................................. 6

SPECIFICATIONS (SV650K7/SV650SK7) ...................................................... 8

SPECIFICATIONS (SV650AK7/SV650SAK7) ................................................. 10

PERIODIC MAINTENANCE SCHEDULE ........................................................ 12

PERIODIC MAINTENANCE CHART ...................................................... 12

MAINTENANCE AND TUNE-UP PROCEDURES ........................................... 13

SPARK PLUG ......................................................................................... 13

THROTTLE VALVE SYNCHRONIZATION............................................. 15

ENGINE COMPONENTS INSPECTION AND SERVICING ............................. 16

PISTON AND PISTON RING .................................................................. 16

THERMOSTAT ........................................................................................ 17

FI SYSTEM DIAGNOSIS .................................................................................. 18

FI SYSTEM WIRING DIAGRAM ............................................................. 18

ECM TERMINAL ..................................................................................... 19

FAIL-SAFE FUNCTION........................................................................... 20

DTC TABLE AND DEFECTIVE CONDITION ......................................... 21

DTC TROUBLESHOOTING .................................................................... 24

THROTTLE BODY............................................................................................ 50

AIR CLEANER AND THROTTLE BODY REMOVAL ............................. 51

THROTTLE BODY DISASSEMBLY ....................................................... 54

THROTTLE BODY CLEANING............................................................... 56

THROTTLE BODY REASSEMBLY ........................................................ 57

AIR CLEANER BOX AND THROTTLE BODY INSTALLATION............ 59

STP SENSOR ADJUSTMENT ................................................................ 60

SAMPLE

2 SV650K7/SK7/AK7/SAK7 (’07-MODEL)

SV650K7/SK7/AK7/SAK7 (’07-MODEL)

CONTENTS

TP SENSOR ADJUSTMENT .................................................................. 61

THROTTLE VALVE SYNCHRONIZATION ............................................ 62

ISC VALVE ............................................................................................. 64

ISC VALVE PRE-SET............................................................................. 65

IGNITION SYSTEM.......................................................................................... 66

INSPECTION .......................................................................................... 66

INTRODUCTION OF ABS (For SV650A/SA).................................................. 68

CAUTIONS IN SERVICING ............................................................................. 72

ABS COMPONENTS ....................................................................................... 75

ABS COMPONENTS LOCATION .......................................................... 75

ABS COUPLER CONNECTION DIAGRAM........................................... 76

ABS WIRING DIAGRAM ........................................................................ 77

ABS UNIT SYSTEM DIAGRAM ............................................................. 78

ABS TROUBLESHOOTING ............................................................................ 79

TROUBLESHOOTING PROCEDURE.................................................... 80

DTC (Diagnostic Trouble Code) OUTPUT ........................................... 89

DTC DELETING AND ABS OPERATION CHECK ................................ 91

USE OF SDS DIAGNOSTIC PROCEDURES......................................... 94

USE OF SDS DIAGNOSIS RESET PROCEDURE ................................ 95

DTC TABLE OF ABS ............................................................................. 101

DTC TROUBLESHOOTING ................................................................... 102

ABS COMPONENT REMOVAL, INSPECTION AND INSTALLATION .......... 119

WIRING HARNESS, CABLE, HOSE ROUTING

AND SENSOR INSTALLATION ...................................................................... 129

THROTTLE BODY INSTALLATION................................................................ 146

REAR FENDER INSTALLATION .................................................................... 147

HEAT SHIELD INSTALLATION ...................................................................... 148

IGNITION COIL INSTALLATION..................................................................... 149

EMISSION CONTROL SYSTEM ..................................................................... 150

EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) .............. 150

PAIR (AIR SUPPLY) SYSTEM INSPECTION ................................................. 151

HEATED OXYGEN SENSOR (HO2S) INSPECTION

(For E-02, 19, 24, 33)....................................................................................... 151

SPECIAL TOOLS............................................................................................. 152

TIGHTENING TORQUE ................................................................................... 152

SERVICE DATA (SV650/S) ............................................................................. 153

SERVICE DATA (SV650A/SA) ........................................................................ 165

WIRING DIAGRAM ........................................................................................... 177

SAMPLE

SV650K7/SK7/AK7/SAK7 (’07-MODEL) 3

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO.

SV650

E-02

E-03

E-19

E-24

E-28

E-33

U.K.

U.S.A. (Except for california)

E.U.

Australia

Canada

California (U.S.A.)

JS1BY111200100001 –

JS1VP53A 72100001 –

JS1BY111100100001 –

JS1BY111300100001 –

JS1VP53A 72100001 –

SV650S

E-02

E-03

E-19

E-24

E-28

E-33

U.K.

U.S.A. (Except for california)

E.U.

Australia

Canada

California (U.S.A.)

JS1BY132200100001 –

JS1VP53A 72100001 –

JS1BY132100100001 –

JS1BY132300100001 –

JS1VP53A 72100001 –

SV650A

E-02

E-03

E-19

E-24

E-28

E-33

U.K.

U.S.A. (Except for california)

E.U.

Australia

Canada

California (U.S.A.)

JS1BY113200100001 –

JS1VP53B 72100001 –

JS1BY113100100001 –

JS1BY113300100001 –

JS1VP53B 72100001 –

SV650SA

E-02

E-03

E-19

E-24

E-28

E-33

U.K.

U.S.A. (Except for california)

E.U.

Australia

Canada

California (U.S.A.)

JS1BY134200100001 –

JS1VP53B 72100001 –

JS1BY134100100001 –

JS1BY134300100001 –

JS1VP53B 72100001 –

SV650U E-19 E.U. JS1BY211100100001 –

SV650SU E-19 E.U. JS1BY222100100001 –

SV650UA E-19 E.U. JS1BY213100100001 –

SV650SUA E-19 E.U. JS1BY224100100001 –

SAMPLE

4 SV650K7/SK7/AK7/SAK7 (’07-MODEL)

ABBREVIATIONS USED IN THIS

MANUAL

A

ABDC : After Bottom Dead Center

ABS : Anti-lock brake system

AC : Alternating Current

ACL : Air Cleaner, Air Cleaner Box

API : American Petroleum Institute

ATDC : After Top Dead Center

A/F : Air Fuel Mixture

B

BBDC : Before Bottom Dead Center

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

C

CKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

CO : Carbon Monoxide

CPU : Central Processing Unit

D

DC : Direct Current

DMC : Dealer Mode Coupler

DOHC : Double Over Head Camshaft

DRL : Daytime Running Light

DTC : Diagnostic Trouble Code

E

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

EVAP : Evaporative Emission

EVAP

Canister

: Evaporative Emission

Canister (Canister)

F

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FPR : Fuel Pressure Regulator

FP Relay : Fuel Pump Relay

G

GEN : Generator

GND : Ground

GP Switch : Gear Position Switch

H

HC : Hydrocarbons

HO2 Sensor : Heated Oxygen Sensor (HO2S)

I

IAP Sensor : Intake Air Pressure Sensor (IAPS)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

IG : Ignition

ISC Valve : Idle Speed control valve (ISCV)

L

LCD : Liquid Crystal Display

LED : Light Emitting Diode

(Malfunction Indicator Lamp)

LH : Left Hand

M

MAL-Code : Malfunction Code

(Diagnostic Code)

Max : Maximum

MIL : Malfunction Indicator Lamp

(LED)

Min : Minimum

SAMPLE

SV650K7/SK7/AK7/SAK7 (’07-MODEL) 5

N

NOx : Nitrogen Oxides

O

OHC : Over Head Camshaft

OPS : Oil Pressure Switch

P

PAIR : Pulsed Secondary Air Injection

PCV : Positive Crankcase

Ventilation (Crankcase Breather)

R

RH : Right Hand

ROM : Read Only Memory

S

SAE : Society of Automotive Engineers

SDS : Suzuki Diagnosis System

STC System : Secondary Throttle Control

System (STCS)

STP Sensor : Secondary Throttle Position

Sensor (STPS)

ST Valve : Secondary Throttle Valve (STV)

STV Actuator : Secondary Throttle Valve Actuator

(STVA)

T

TO Sensor : Tip Over Sensor (TOS)

TP Sensor : Throttle Position Sensor (TPS)

SAMPLE

6 SV650K7/SK7/AK7/SAK7 (’07-MODEL)

SAE-TO-FORMER SUZUKI TERM

This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in

this manual in compliance with SAE recommendations, as well as their former SUZUKI names.

SAE TERM

FORMER SUZUKI TERM

FULL TERM ABBREVIATION

A

Anti-lock brake system ABS Anti-lock brake system

Air Cleaner ACL Air Cleaner, Air Cleaner Box

B

Barometric Pressure BARO Barometric Pressure, Atmospheric

Pressure (APS, AP Sensor)

Battery Positive Voltage B+ Battery Voltage, +B

C

Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),

Crank Angle

D

Data Link Connector DLC Dealer Mode Coupler

Diagnostic Test Mode DTM ––––

Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code

E

Electronic Ignition El ––––

Engine Control Module ECM Engine Control Module (ECM)

Fl Control Unit, Engine Control Unit (ECU)

Engine Coolant Level ECL Coolant Level

Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem-

perature, Water Temperature

Engine Speed RPM Engine Speed (RPM)

Evaporative Emission EVAP Evaporative Emission

Evaporative Emission Canister EVAP Canister –––– (Canister)

F

Fa n C o n t r o l F C ––––

Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge

Fuel Pump FP Fuel Pump (FP)

G

Generator GEN Generator

Ground GND Ground (GND, GRD)

H

Heated Oxygen Sensor HO2S Heated Oxygen Sensor (HO2S), O2 Sensor

SAMPLE

SV650K7/SK7/AK7/SAK7 (’07-MODEL) 7

SAE TERM

FORMER SUZUKI TERM

FULL TERM ABBREVIATION

I

Idle Speed Control ISC ––––

Idle Speed Control Valve –––– ISC Valve

Ignition Control IC Electronic Spark Advance (ESA)

Ignition Control Module ICM ––––

Intake Air Temperature IAT Intake Air Temperature (IAT), Air Tempera-

ture

M

Malfunction Indicator Lamp MIL LED Lamp

Malfunction Indicator Lamp (MIL)

Manifold Absolute Pressure MAP Intake Air Pressure, Intake Vacuum

Mass Air Flow MAF Air Flow

O

On-Board Diagnostic OBD Self-Diagnosis Function

Diagnostic

Open Loop OL ––––

P

Programmable Read Only Memory PROM ––––

Pulsed Secondary Air Injection PAIR Pulse Air Control (PAIR)

Purge Valve Purge Valve Purge Valve (SP Valve)

R

Random Access Memory RAM ––––

Read Only Memory ROM ROM

S

Secondary Air Injection AIR ––––

Secondary Throttle Control System STCS STC System (STCS)

Secondary Throttle Valve STV ST Valve (STV)

Secondary Throttle Valve Actuator STVA STV Actuator (STVA)

T

Throttle Body TB Throttle Body (TB)

Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)

Throttle Position Sensor TP Sensor TP Sensor (TPS)

V

Voltage Regulator VR Voltage Regulator

Volume Air Flow VAF Air Flow

SAMPLE

8 SV650K7/SK7/AK7/SAK7 (’07-MODEL)

SPECIFICATIONS (SV650K7/SV650SK7)

DIMENSIONS AND DRY MASS

Overall length....................................................... 2 080 mm (81.9 in) ........................ SV650

2 085 mm (82.1 in) ........................ SV650S

Overall width ........................................................ 745 mm (29.3 in) ........................ SV650

730 mm (28.7 in) ........................ SV650S

Overall height....................................................... 1 085 mm (42.7 in) ........................ SV650

1 170 mm (46.1 in) ........................ SV650S

Wheelbase ........................................................... 1 440 mm (56.7 in) ........................ SV650

* 1 425 mm (56.1 in) ........................ SV650S

Ground clearance ................................................ 150 mm (5.9 in) .......................... SV650

155 mm (6.1 in) .......................... SV650S

Seat height........................................................... 800 mm (31.5 in)

Dry mass..............................................................* 168 kg (370 lbs).......................... SV650

* 172 kg (379 lbs).......................... SV650S

ENGINE

Type ..................................................................... 4-stroke, liquid-cooled, DOHC,

90°-degree V-twin

Number of cylinders ............................................. 2

Bore ..................................................................... 81.0 mm (3.189 in)

Stroke................................................................... 62.6 mm (2.465 in)

Displacement ....................................................... 645 cm

3

(39.4 cu. in)

Compression ratio................................................ 11.5 : 1

Fuel system.......................................................... Fuel injection

Air cleaner............................................................ Non-woven fabric element

Starter system...................................................... Electric

Lubrication system ............................................... Wet sump

Idle speed ............................................................ 1 300 ± 100 r/min

DRIVE TRAIN

Clutch................................................................... Wet multi-plate type

Transmission........................................................ 6-speed constant mesh

Gearshift pattern .................................................. 1-down, 5-up

Primary reduction ratio......................................... 2.088 (71/34)

Gear ratios, Low ................................................ 2.461 (32/13)

2nd................................................. 1.777 (32/18)

3rd ................................................. 1.380 (29/21)

4th.................................................. 1.125 (27/24)

5th.................................................. 0.961 (25/26)

Top ................................................ 0.851 (23/27)

Final reduction ratio ............................................. 3.000 (45/15)................................. SV650

* 3.000 (45/15)................................. SV650S

Drive chain ........................................................... DID 525V8, 110 links..................... SV650

DID 525V8, 108 links..................... SV650S

SAMPLE

SV650K7/SK7/AK7/SAK7 (’07-MODEL) 9

CHASSIS

Front suspension................................................. Telescopic, coil spring, oil damped

Rear suspension ................................................. Link type, coil spring, oil damped

Front fork stroke .................................................. 130 mm (5.1 in) .............................SV650

125 mm (4.9 in) .............................SV650S

Rear wheel travel ................................................ 137 mm (5.4 in) .............................SV650

134 mm (5.3 in) .............................SV650S

Caster.................................................................. 25°

Trail ..................................................................... 102 mm (4.02 in) ...........................SV650

100 mm (3.94 in) ...........................SV650S

Steering angle ..................................................... 32° (right & left)..............................SV650

30° (right & left)..............................SV650S

Turning radius ..................................................... 3.0 m (9.8 ft) ..................................SV650

3.2 m (10.5 ft) ................................SV650S

Front brake.......................................................... Disc brake, twin

Rear brake .......................................................... Disc brake

Front tire size ...................................................... 120/60 ZR17 M/C (55W), tubeless

Rear tire size ....................................................... 160/60 ZR17 M/C (69W), tubeless

ELECTRICAL

Ignition type......................................................... Electronic ignition (Transistorized)

Ignition timing ...................................................... * 8° B.T.D.C. at 1 300 r/min

Spark plug ........................................................... NGK CR8E or DENSO U24ESR-N

Battery................................................................. 12 V 36.0 kC (10 Ah)/10 HR

Generator ............................................................ Three-phase A.C. generator

Main fuse............................................................. 30 A

Fuse .................................................................... 10/10/15/10/10/10 A ......................SV650

15/15/15/10/10/10 A ......................SV650S

Headlight ............................................................. 12 V 60/55 W (H4).........................SV650

12 V 60/55 W (H4) × 2...................SV650S

Position/Parking light........................................... 12 V 5 W......Except E-03, 24, 28, 33.......... SV650

12 V 5 W × 2................................................ SV650S

Brake light/Taillight .............................................. LED

Licence plate light ............................................... 12 V 5 W

Turn signal light................................................... 12 V 21 W

Speedometer light ............................................... LED

Tachometer light ................................................. LED

Turn signal indicator light .................................... LED

Neutral indicator light .......................................... LED

High beam indicator light..................................... LED

Oil pressure/Coolant temperature/

Fuel injection indicator light................................. LED

Fuel indicator light ............................................... LED

CAPACITIES

Fuel tank, including reserve ................................ 16.0 L (4.2/3.5 US/lmp gal)..........E-33

17.0 L (4.5/3.7 US/lmp gal)..........Others

Engine oil, oil change ........................................ 2 300 ml (2.4/2.0 US/lmp qt)

with filter change.............................. 2 700 ml (2.9/2.4 US/lmp qt)

overhaul ........................................... 3 100 ml (3.3/2.7 US/lmp qt)

Coolant ......................................................... 1.7 L (1.8/1.5 US/lmp qt)

These specifications are subject to change without notice.

SAMPLE

10 SV650K7/SK7/AK7/SAK7 (’07-MODEL)

SPECIFICATIONS (SV650AK7/SV650SAK7)

DIMENSIONS AND DRY MASS

Overall length..................................................... ** 2 120 mm (83.5 in) ........................ SV650A

** 2 120 mm (83.5 in) ........................ SV650SA

Overall width ........................................................ 745 mm (29.3 in) ........................ SV650A

730 mm (28.7 in) ........................ SV650SA

Overall height....................................................... 1 085 mm (42.7 in) ........................ SV650A

1 170 mm (46.1 in) ........................ SV650SA

Wheelbase ......................................................... ** 1 470 mm (57.9 in) ........................ SV650A

** 1 470 mm (57.9 in) ........................ SV650SA

Ground clearance .............................................. ** 155 mm (6.1 in) .......................... SV650A

155 mm (6.1 in) .......................... SV650SA

Seat height........................................................... 800 mm (31.5 in)

Dry mass............................................................ ** 171 kg (376 lbs).......................... SV650A

** 175 kg (385 lbs).......................... SV650SA